MASTERVOLT 40 Charge Mate Pro Electronic Charge Relay Installation Guide
- June 5, 2024
- MASTERVOLT
Table of Contents
CHARGE MATE PRO
40, 90
CURRENT LIMITED ELECTRONIC CHARGE RELAY
USER AND INSTALLATION MANUAL
Charge Mate Pro
- fuse ** resistor
Specifications
| Model (hardware version C and higher) | 83304002 / 83309002 |
|---|---|
| Weight | 0.7 kg |
1.5 lb
Dimensions| 157 x 140 x 80 mm
6.2 x 5.5 x 3.1 in
Input voltage| 9-32 VDC
Operation temperature| -40 to 60 °C
-40 to 148 °F
Maximum output current| 40 A / 90 A
Maximum voltage drop| 0.2 V
Maximum allowed voltage difference| 8 V @ 12 V /
16 V @ 24 V
Maximum current Status output| 1 A
Automatic 12/24V detection
Switch on voltage| >13,5 V @12 V /
27 V @ 24 V
---|---
Switch on delay time| 5 s
Switch off voltage| <12.75 V @ 12 V /<25.50 V @ 24V
Switch off delay time| 2.5 s
Recommended wire sizes for wire lengths up to 3 meters (10 ft) (DIN 47750)
| DC Current | Wire size |
|---|---|
| 25 – 75 Amp | 16 mm ² |
(AWG 4)
75 – 100 Amp| 25 mm² (AWG 3)
100 – 140 Amp| 35 mm² (AWG 1-2)
140 – 200 Amp| 50 mm² (AWG 0)
Ground wire size| 4 mm ²
Cable length (DC in + DC out)| <5m: Recommended
5-20m: Might affect charging duration (see
installation instructions)
20m: Not recommended
Charge Mate Pro
The Charge Mate Pro is a current limited electronic charge relay for the
distribution of charge current between two battery banks. The battery banks
are connected when the voltage rises above a pre-set value for at least 5
seconds. When the voltage drops the battery banks are isolated again. With an
optional remote control switch, the Charge Mate Pro can be used as a switch
for emergency starts of the motor. This will overrule the automatic function.
Only use battery banks with the same type of charge characteristics.
The Charge Mate Pro can only be applied in 12 VDC or 24 VDC installations with
a common negative.
Safety regulations and measures
Install the Charge Mate Pro according to the instructions in this manual. The
Charge Mate Pro must be used in accordance with the specifications Connections
and safety features must be executed according to the locally applicable
regulations. Use cables with appropriate size wire and keep the cable
connections as short as possible. Use reliable terminals and fasten the bolts
tightly, but do not over torque. Examine your electrical installation on a
regular base, at least once a year. Defects such as loose connections, burnt
wiring etc. must be corrected immediately.
Liability
Mastervolt can accept no liability for:
- Consequential damage resulting from the use of the Charge Mate Pro.
- Possible errors in the included manual and the consequences of these.
- Use that is inconsistent with the purpose of the product.
Warranty
Mastervolt assures the product warranty of the Charge Mate Pro for two years
after purchase, on the condition that the product is installed and used
according to the instructions in this manual. Installation or use not
according to these instructions may result in underperformance, damage or
failure of the product and may void this warranty. The warranty is limited to
the cost of repair and/or replacement of the product. Costs for labor or
shipping are not covered by this warranty.
Correct disposal of this product
This product is designed and manufactured with high-quality materials and
components, which can be recycled and reused. Please be informed about the
local separate collection system for electrical and electronic products.
Please act according to your local rules and do not dispose of your old
products with your normal household waste. The correct disposal of your old
product will help prevent potential negative consequences to the environment
and human health.
Installation
-
To prevent hazardous situations, turn off the electrical power and make sure that no load is connected to the batteries during installation.
-
The Charge Mate Pro must be installed in a well-ventilated environment, as high currents will heat up the Charge Mate Pro. Preferably on a flat metal surface, with the fins vertical.
Do not install the Charge Mate Pro directly above the batteries because of possible corrosive sulfur fumes. -
Use the mounting template from the packaging to determine the exact location and screw holes.
-
Check the installation drawing for the correct connection. Note that to keep the drawing easy to read, the cable lengths have not been drawn in proportion to each other.
-
Install the Charge Mate Pro in the positive lead between the battery banks. To prevent high cable inductance, resulting in reduced charge current or even shut down of the Charge Mate Pro, make sure that all cables are as short as possible and free from loops, and run the positive and negative cables as close as possible together
-
Connect the negative of the battery banks to the Charge Mate Pro.
-
Optionally you can install a remote status light to the Status output and A+.
Remote switch (optional)
Optionally you can install a single pole ON-OFF-ON switch for remote operation
of the Charge Mate
Pro, see installation drawing on page 2.
Remote switch functions
ON| Switches input to 12/24 V.
The battery banks are connected in parallel and bi-directional.
---|---
PULSE| Switches input to 12/24 V for a short time.
Emergency start (battery banks are connected for 30 seconds)
OFF| Switches input to Ground. The Charge Mate Pro is switched off.
AUTOMATIC| Let the Switch input floating (or no switch connected).
Default automatic mode with 40A / 90A fixed current limit.
LED indicators
| LED | Meaning |
|---|
green| Blinking: starting up
Solid on: on (electrical connection between A+ and B+).
red 1 x blinking + green solid on| Working with reduced charge current
Reduced charge current (resulting in extended charge time) to protect the
Charge Mate Pro. Most likely, this is due to long cable lengths. Check that
the
cables are as short as possible, free from loops and run the positive and
negative wires as close as possible together.
red 1 x blinking
| Overvoltage
The voltage on A+ and/or B+ has been above 15.5/31 V for more than 1 s.
The warning disappears when voltage drops below 15/30 V for more than 10
s.
red 2 x blinking| High voltage differential
A voltage differential between A+ and B+ has been detected of more than
8/16 V for more than 2.5 s. The warning disappears when the voltage
differential drops below 8/16 V for more than 2.5 s.
red 3 x blinking| Temperature too high (75 °C / 167 °F)
This warning disappears when the temperature drops below 65 °C/ 149 °F.
red 4 x blinking| Reverse current
Reverse current detected from B+ to A+ for more than 2s. Disappears after
20 s.
red 5 x blinking| Installation error
Shut down to protect the Charge Mate Pro. Most likely, this is due to long
cable lengths. Check that the cables are as short as possible, free from loops
and run the positive and negative wires as close as possible together.
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Document version: 10000010901/04 (July 22)
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